Snapped Manifold bolts :(

[Ben Lessani]

I have used a couple of sets of stud extractor kits, the grabit type and some halfords ones. Both times they have snapped when trying to remove the bolts

Can't understand how its remotely possible to snap a stud extractor - they're sturdier than a standard socket. (See image).

But if the manifold is still stuck to the head even though all the other nuts have been removed, you won't have enough room to get it on. You sure its not just binding on some rusty studs? I'd lever it off with a screwdriver tbh.

[danny_p]

if youve got all the bolts on the inlet  HIT IT it'll  be stuck on with corrosion down the bolt hole.   

[bmouthboyo]

The inlet is loose, as in i can pivot it up and down around the snapped bolt but it wont prise away from it. I guess the manifold itself does not having any thread so it must be the bolt.

Given that the other bolts for the inlet came off pretty easily compared to the really stiff now snapped one i reckon the previous person to install it had it at a bit of an angle. Hence why the inlet wont just slide off.

I think i might try grinding the few mm of bolt back and try getting the inlet off. Basically the inlet is moving about but that snapped bolt is somehow holding it in place and that end.

[Ben Lessani]

I wouldn't grind any of it off if you can avoid it - you need as much thread possible to remove it. If its just held on by one rusty stud - lever it off.

Otherwise you're drilling and tapping it - which is a pig to get centred.

[danny_p]

no need for the grinder ( yet anyway )   the bolt may have been crosstheaded explaning why it snaped  but more likely a hole load of electroltic corosion binding whats left of the bolt to the manifold, sadly golf are getting to the age where these classic car problems start to appear    a good blowtorch is a good freind to have in the workshop  so is plenty of plus gas. 

heat it them move it about then oil it and then go back to heat.  you should notice it start to free up then hopefully all the corrosion will fall out and it'll pop off then you'll wonder what the hell was holding it.

[bmouthboyo]

ok i think the heat route is what i need.

Will it be ok applying heat when the bolt is in a aluminum head? it wont expand and damage the head will it?

Regarding the heat, do you have any links or know where i can get a cheap option? I have seen someone using a small acetylene can attached to a torch on a video. Any idea on prices and where i can get one etc

Once the manifolds are off is it relatively easy to get the bolts out if they are protruding a fail bit?

[danny_p]

i've done it enough times,   Ali expands faster than steel and ali also conducts heat somethign spectial.   so you will struggel to make a hot spot on the head even if you try. 

the small gas torch you have seen been used is proably a plumbers torch useing MAPP gas.   they are highly recomended

http://cgi.ebay.co.uk/Rothenberger-Superfire-2-Soldering-Torch-Mapp-Gas_W0QQitemZ120416638130QQcmdZViewItemQQptZUK_DIY_Materials_Plumbing_MJ?hash=item120416638130&_trksid=p3286.c0.m14&_trkparms=72%3A1683|66%3A2|65%3A12|39%3A1|240%3A1318|301%3A1|293%3A1|294%3A50

there not that cheep but in a diffrent league to the torches with the other type of disposable cylinder.  gas is quite expensive as well  as the cartages are much tougher  but the cheep spin on cartages arn't safe in a workshop  i have accidentaly poped a couple before these things you can beat and ll they'll do is dent also the flame has some good heat in it.   no where near what a oxy torch has  but for oxiy torch your looking £300 to buy regs pipes and torch  + £114 per yer bottel rent

[sidecarphil]

if it was me i would remove the head and warm the studs with gas bottles and work them out with mole grips

the problem you have is that the studs may just snap again but if you can get some warmth into them then your laughing

heat is the key to getting these out i think 

[bmouthboyo]

Ok thats good news, i am thinking about ordering:

Blowtorch
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=180316355371#ebayphotohosting

And i have already ordered some plusgas
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWNX:IT&item=310140816590

Also some easy out just in case of a last resort (although i'm very reluctant to try due to snapage)

Will the temperature from the blowtorch be enough you think?

[sidecarphil]

that blow torch wont get hot enough to burn your fingers 

you really need the stud glowing , but be carefull because alloy just melts without warning if it gets too hot !!!

i have one of those blow torches although it is a snap-on one and they are designed for melting shrink wrap